Project
Integration of a heat exchanger in a petrochemical plant.
Client
Nippon Gases
Location
Barcelona, Spain
Service
Engineering
Sector
Oil&Gas
Disciplines
Piping Engineering
Year
2021- 2022
Duration
1 año
Software
Cadworx, Navisworks
Integration of a heat exchanger in a petrochemical plant.
IDEA is contracted to carry out the integration of the heat exchanger in the T-285 plant at the facilities of the company Nippon Gases SLU (NG) in Castellbisbal.
The main tool used to execute the project was the point cloud generated with 3D scanning, facilitating the collection of site data to create the design, modelling and issuing of the necessary documentation for the legalisation and execution of the project.
Work performed
The work performed at the client’s facilities consisted of scanning by Laser Scanner.This technology is used to generate point clouds, which are the basis for the 3D modelling of the affected area and for the insertion of the new equipment, the relevant disconnections and the new connections of the air, water and gas instrument lines.
The existing heat exchangers to be disconnected have been taken into account and the layout of the new equipment should facilitate their proper maintenance of that of the surrounding equipment.
The new foundations and supporting structure also had to be built
With all the data, the stress calculations for manufacturing/assembly and as-built documentation of the investment were carried out, bearing in mind at all times that the accessories to be used follow the specifications of Nippon Gases.
Prior to the manufacture of all the elements that make up the entire installation, we checked that all the dimensions of the project coincided with the existing elements.
Scoop
The scope of the services that IDEA Ingeniería offered to meet the needs of NIPPON, at its Cartagena industrial complex, for the tender for the WARM END UPGRADE CASTELBISBAL ENGINEERING works is as follows:
- PROCESS
– Updating piping and instrumentation diagrams (P&IDs) of processes and ancillary services.
– Adjustment of equipment implementation plans (plot plan).
– Data sheet for process equipment, package units and auxiliary equipment.
– List of equipment, process lines and ancillary services.
– Technical specifications, equipment drawings and package units.
– 3D model of the plant. (Any modelling software may be used). - CIVIL/STRUCTURE/ARCHITECTURE
– Earthworks planning (backfilling, cutting).
– Design and calculation of civil structures.
– Structural and construction plans.
– Detailed plans of civil works.
– Planimetry of foundations.
– Particular technical specifications.
– Architectural plans (floor plans, elevations, cuts, details etc.).
– Calculation memories.
– Metric computations (measurements) - PIPING
– Piping layout plan for the entire plant.
– Pipe flexibility analysis for diameters greater than 8 inches.
– Pipe routing and assembly plans (layout).
– Technical specifications for pipes and valves.
– Piping isometrics (including list of materials, insulation and hydraulic testing requirements).
– Detailed list of final Tie-ins.
– Preparation of technical specifications for insulation, interior cladding and painting.
– Accessibility study of equipment and instruments in the field
– List of minor materials and consumables.
– Development of start-up procedures (pre-commissioning and commissioning). - INSTRUMENTATION AND CONTROL
– Location of instruments.
– List of instruments.
– Distribution of instrumentation and control cabling (trunking, tray, underground etc.).
– Planimetry of instrumentation cable distribution and pneumatic connections.
– List of instrumentation cables.
– List of monitoring (local and remote), control and protection signals.
– Final as-built drawings.
Project phases:
- Scanning at client site of affected area.
- Modelling of new installation and modifications to be made.
- Verification with calculation of the installation design.
- Issuance of plans and documentation for the execution of the installation.
- Supervision of the execution of the works.
- Drafting of as-built documentation.
The main tool used was the point cloud generated by 3D scanning, facilitating the collection of site data to create the design, modelling and issuing of documentation.
This project has been executed completely without incident, according to the schedule, scope and quality initially envisaged.
It is a clear example that defines us as experts in modelling new modifications to existing installations, using the point cloud from a scan of the current plant, which allows us to accurately determine all the dimensions of existing equipment. With this we obtain :
- An accurate view of the finished installation, on which the impact on the original installation can be seen;
- Detailed construction plans that maximise workshop fabrication and minimise fieldwork, improving the time and quality of the work.
Much more than engineering.
Much more than engineering.
